Masonry unit for constructing a multi-wythe wall

ABSTRACT

A masonry unit for constructing a wall is disclosed. The masonry unit includes at least three substantially vertical parallel partitions. Each of the partitions connects to an adjacent partition by a web thereby defining a pair of oppositely-facing open-ended recesses on either side of the web. Each of the webs connecting the partitions is offset from any adjacent webs in the masonry unit. A plurality of separated continuous vertical cavities extending through multiple layers of stacked masonry units are formed within the wall when positioning the multiple layers of stacked masonry units on top of each other in a horizontally offset and vertically inverted manner.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional PatentApplication No. 61/326,346 filed Apr. 21, 2010, the disclosure of whichis hereby incorporated by reference in its entirety.

STATEMENT CONCERNING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

FIELD OF THE INVENTION

This invention generally relates to masonry materials, particularlymasonry units for constructing multi-wythe walls.

BACKGROUND OF THE INVENTION

Masonry units (e.g., clay or concrete bricks or blocks) have been usedfor many years in the construction of building walls. To form a wall,multiple masonry units are typically stacked vertically withcementitious mortar materials placed between them in order topermanently bind the units together. In many cases, the masonry unitsare stacked in a single-wythe structure (i.e., a structure having awidth of one masonry unit). While single-wythe walls are popular andrelatively easy to construct, increasingly demanding building codes nowrequire wall systems with greater structural integrity, increasedthermal resistance, and improved moisture control.

These requirements have proven difficult to meet, both physically andeconomically, using single-wythe wall designs. Consequently, theindustry has begun to utilize multi-wythe masonry wall systems andcavity wall systems. These systems allow for steel reinforcement withinthe wall, greater levels of thermal insulation, and air spaces thatallow intrusive moisture to be controlled and channeled out of the wallto the building's exterior.

Such wall systems typically include two or more separately-constructedwalls that together form the composite wall. Such composite walls aretypically constructed by first building a concrete masonry wall,applying a layer of insulating material to the exterior surface of themasonry wall, and then building a second wall (sometimes called a veneerwall) that is spaced from the first wall. The two masonry walls aretypically mechanically tied together with metal wires or tabs placed inthe horizontal mortar joints of both walls. An air space may be leftbetween the insulation of the first wall and the second wall to define acavity wall or a rain screen wall that permits the ventilation of airbetween the two walls. The wall system may also be reinforced withvertical steel rods running through the cores of the masonry units,horizontal steel rods, and/or horizontal ladder wires.

The construction of a composite wall of this type is typically timeconsuming and labor intensive. Because the two walls are buildsequentially, the construction of the veneer wall depends on thecompletion on the concrete masonry wall. Moreover, when vertical steelreinforcement rods are utilized during construction, masons musttypically lift the heavy masonry units to thread their cavities over thetop of fixed vertical rods. Because vertical rods are typically four toeight feet in length, this task can be very strenuous.

Hence, there is a need for an improved masonry unit that facilitatesconstruction of a multi-wythe wall.

SUMMARY OF THE INVENTION

In one aspect, the present invention provides a masonry unit forconstructing a wall. The masonry unit comprises at least threesubstantially vertical parallel partitions extending along a lengthwisedirection. Each of the partitions connects to an adjacent partition by aweb extending in a widthwise direction, thereby defining a pair ofoppositely-facing open-ended recesses on either side of the web. Each ofthe webs connecting the partitions is offset in a lengthwise directionfrom any adjacent webs in the masonry unit. When a wall is formed from aplurality of the masonry units by positioning multiple rows of stackedmasonry units on top of each other in a horizontally offset andvertically inverted manner, a plurality of separated continuous verticalcavities extending through the multiple rows are formed within the wall.

In some forms, the masonry unit may further include avertically-extending support formed along one at least one of thepartitions to provide support for the partition during fabrication ofthe masonry unit. The vertically-extending support may be aligned withone of the webs in the lengthwise direction. If mortar is applied to thetop surface and bonds the unit to the unit above, thevertically-extending support may further lend additional load-bearingcapacity to the overall wall system.

In some forms, the masonry units may be configured such that, if asecond row of masonry units is stacked on top of a first row of masonryunits in a vertically inverted manner and are horizontally offsetapproximately one-half of an overall length of the masonry unit from thefirst row, then the webs of the masonry units in the first row and thesecond row are vertically aligned with one another. Each of the webs maybe offset from any adjacent webs in the lengthwise direction of themasonry unit by substantially one half of an overall length of themasonry unit. Moreover, each of the webs may be offset from ends of thepartitions in the lengthwise direction of the masonry unit bysubstantially one quarter of an overall length of the masonry unit.Because some mortar may be inserted between the blocks, the one-half andone-quarter offsets may be approximate.

In some forms, at least one web may include a vertically facingopen-ended slot configured to receive a horizontal reinforcement rod.

In some forms, the partitions and the webs may comprise cement and eachof the partitions may integrally connect to the adjacent partitions bythe webs.

In some forms, the masonry unit is generally rectangular shaped. In thisway, when a wall is formed, these masonry units may maintain anaesthetic consistent with conventional masonry units and, moreover, maybe made to easily interface with standard corners, end pieces, and otherfittings.

A masonry unit of this type offers many advantages over conventionalconcrete masonry units with closed cavities. With the improved masonryunit, a wall can be constructed with multiple layers in manner that isfar easier than the construction of a conventional composite wall.Whereas conventional composite walls require the sequential building ofat least two walls with a space there between, by using the disclosedmasonry unit the same effect can be achieved with the construction of asingle wall. Moreover, because the masonry unit has open-sided cores,the masonry units do not need to be lifted over the top of verticalreinforcement rods during construction. This reduces the amount oflifting necessary to build the wall and eliminates the amount ofreinforcement rod material required (as longer continuous lengths ofreinforcement material can be utilized).

The masonry units can be used to form a wall with separated continuousvertical cavities. Some of these cavities can serve as a rain screenwall to control moisture and/or provide ventilation to avoid mold andmaintain healthy building structures. Additionally, these cavities canreceive insulation, receive reinforcement materials to strengthen thewall, and/or house utilities such as plumbing lines, electrical cables,and so forth.

Additionally, this single wall has superior thermal and acoustictransmission properties that are not found in walls constructed withmasonry units in which the webs directly connect a front and rear faceof the wall.

The foregoing and advantages of the invention will appear in thedetailed description which follows. In the description, reference ismade to the accompanying drawings which illustrate a preferredembodiment of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will hereafter be described with reference to theaccompanying drawings, wherein like reference numerals denote likeelements, and:

FIG. 1 is a perspective view of a first embodiment of a masonry unitaccording to the present invention;

FIG. 2 is a bottom view of the masonry unit of a second embodimentsimilar to the unit of FIG. 1;

FIG. 3 is a perspective view of a third embodiment of a masonry unitaccording to the present invention;

FIG. 4 is a perspective view of a fourth embodiment of a masonry unitaccording to the present invention;

FIG. 5 is a perspective view of a fifth embodiment of a masonry unitaccording to the present invention;

FIG. 6 is a top view of an upper row of masonry units according to thepresent invention to be placed on a lower row of masonry units accordingto the present invention;

FIG. 7 is a top view of the upper row of masonry units of FIG. 6 beingpositioned on the lower row of masonry units;

FIG. 8 is a top view of the upper row of masonry units of FIG. 6positioned on the lower row of masonry units;

FIG. 9 is a side view of the upper row of masonry units of FIG. 6positioned on the lower row of masonry units;

FIG. 10 is an exploded perspective view of a wall of masonry unitsaccording to the present invention including vertical reinforcementrods;

FIG. 11 is an exploded perspective view of a wall of masonry unitsaccording to the present invention including insulation;

FIG. 12 is an exploded perspective view of a wall of masonry unitsaccording to the present invention including a horizontal reinforcementrod;

FIG. 13 is an exploded perspective view of a wall of masonry unitsaccording to the present invention including two horizontalreinforcement rods;

FIG. 14 is a top view of a wall of masonry units according to thepresent invention including a horizontal “ladder” reinforcementstructure;

FIG. 15 is a top view of a wall of masonry units according to thepresent invention including a horizontal “truss” reinforcementstructure;

FIG. 16 is an exploded perspective view of a wall of masonry unitsaccording to the present invention including a vertical reinforcementrod and insulation;

FIG. 17 is a top view of a wall of masonry units according to thepresent invention including a horizontal “truss” reinforcementstructure, insulation, and vertical reinforcement rods and groutproximate an interior surface of the wall;

FIG. 18 is a top view of a wall of masonry units according to thepresent invention including a horizontal “truss” reinforcementstructure, insulation, and vertical reinforcement rods and groutproximate an interior surface and an exterior surface of the wall;

FIG. 19 is a top view of a wall of masonry units according to thepresent invention including a horizontal “truss” reinforcementstructure, vertical reinforcement rods and grout proximate an interiorsurface of the wall, and insulation that defines air gaps proximate anexterior surface of the wall;

FIG. 20 is a top view of a wall of masonry units according to thepresent invention including a horizontal “truss” reinforcementstructure, vertical reinforcement rods and grout proximate an interiorsurface and an exterior surface of the wall, and insulation that definesair gaps proximate the exterior surface of the wall; and

FIG. 21 is an exploded perspective view of a wall of masonry unitsaccording to the present invention illustrating one of the separatedcontinuous vertical cavities.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring generally to the figures, a masonry unit according to thepresent invention facilitates improved construction of a wall comparedto previous masonry unit designs. Masonry units according to the presentinvention, when constructed to form a single wall, provide propertiesand advantages of a multi-wythe and/or a cavity-wall system. In thefollowing paragraphs, the structure of masonry units according to thepresent invention are first described. Thereafter, walls made frommasonry units according to the present invention are described infurther detail.

Referring first to FIG. 1, an exemplary masonry unit 10 is illustratedwhich is generally rectangular in overall form. The masonry unit 10includes three generally parallel, vertically-extending partitions 12 a,12 b, and 12 c that span the length and height of the masonry unit 10.The first, second, and third partitions 12 a, 12 b, and 12 c are spacedapart from each other in a width direction of the masonry unit 10 togenerally define gaps or spaces there between. To connect the partitions12 a, 12 b, and 12 c in the width direction, the masonry unit 10 furtherincludes two integral, generally parallel, and vertically-extendingconnecting webs 14 a and 14 b. A first connecting web 14 a integrallyconnects the first partition 12 a and the second partition 12 b, and asecond connecting web 14 b integrally connects the second partition 12 band the third partition 12 c. As shown, both of the connecting webs 14 aand 14 b extend from a top face to a bottom face of the masonry unit 10.

The connecting webs 14 a and 14 b are spaced from horizontally-facingends 16 a, 16 b, and 16 c of the partitions 12 a, 12 b, and 12 c todefine, together with the partitions 12 a, 12 b, and 12 c, oppositelyfacing recesses 18 a, 18 b, 20 a, and 20 b on the ends of the masonryunit 10. These recesses 18 a, 18 b, 20 a, and 20 b are generallyU-shaped, extend inwardly from the horizontally-facing ends 16 a, 16 b,and 16 c, and are the fully height of the masonry unit 10. During theconstruction of a wall, these side-accessible recesses or open-sidedcores permit the masonry unit 10 to be moved horizontally relative to avertical reinforcement rod to receive the rod in one of the recesses 18a and 18 b. This feature significantly reduces the amount of liftingrequired for constructing a wall using masonry units 10 compared totraditional masonry units with cavities/cores that are centrallydisposed in the masonry unit and which are closed except on the top andbottom faces of the masonry unit.

In addition to the benefit of reduced labor during construction, thisopen-sided core design also allows for the use of longer verticalsupports because overhead lifting is not required. This means thatoverlaps, ties and couplers do not need to be used to join separateshorter vertical supports and reduces the amount of vertical supportmaterial needed.

To accommodate the formation of separated continuous vertical cavitiesin a wall constructed from the masonry units 10 in which adjacent rowsof masonry units 10 are offset by one-half length, the webs 14 a and 14b are preferably spaced apart from each other in a length direction ofthe masonry unit 10 by about one-half of the overall length of thepartitions 12 a, 12 b, and 12 c. The webs 14 a and 14 b are alsopreferably spaced apart from the horizontally-facing ends 16 a, 16 b,and 16 c of the partitions 12 a, 12 b, and 12 c by about one-quarter ofthe overall length of the partitions 12 a, 12 b, and 12 c. To accountfor the mortar between the units, the distance between the webs 14 a and14 b may be slightly greater than one-half of the length of unit 10 andthe distance from the webs 14 a and 14 b to the nearest ends 16 a, 16 b,and 16 c may be slightly less than one-quarter length. Such dimensionsprovide a well-balanced structure about both horizontal axes, whichfacilitates ease of handling and installation. Such dimensions alsoprovide additional advantages when constructing a wall using multiplemasonry units 10 as described in further detail below.

In addition to the partitions 12 a, 12 b, and 12 c and the webs 14 a and14 b, the masonry unit 10 further includes vertically-extending supports21 a and 21 b that integrally connect to and are disposed on the firstand third partitions 12 a and 12 c, respectively. These supports 21 aand 21 b are positioned along the inwardly facing side of the partitions12 a and 12 c in the recesses 18 a and 18 b in a region in which thepartitions 12 a and 12 c are largely otherwise unsupported (i.e., notdisposed near the webs 14 a and 14 b). The supports 21 a and 21 bprovide support for the first and third partitions 12 a and 12 c,respectively, when initially fabricating the masonry unit 10. Further,in a wall formed from the masonry units the supports 21 a and 21 b maybe respectively aligned with the first and second webs 14 a and 14 b insuch a manner that the supports 21 a and 21 b may also be verticallyaligned with one another when the units 10 are stacked.

The interfaces or corners between the partitions 12 a, 12 b, and 12 c,webs 14 a and 14 b, and supports 21 a and 21 b are preferably curved orradiused to reduce stress concentrations and cracking at the interfaces.In some embodiments, such as the embodiment depicted in FIG. 2, thepartitions 12 a, 12 b, and 12 c may have a greater or increasedthickness near the webs 14 a and 14 b. Among other things, thisincreased thickness may help to strengthen the partition-web connection.However, in some embodiments, such as the embodiment of the masonry unit110 shown in FIG. 3, the interfaces may have squared corners between thepartitions 12 a, 12 b, and 12 c, webs 14 a and 14 b, and supports 21 aand 21 b.

Referring now to FIG. 4, in some embodiments the masonry unit 210includes horizontally-facing ends 16 a, 16 b, and 16 c withvertically-extending, open-ended notches 22 a, 22 b, and 22 c,respectively. The notches 22 a, 22 b, and 22 c may receive mortar whenadditional masonry units 210 are positioned adjacent the ends 16 a, 16b, 16 c of the masonry unit 210 to form a wall. The notches 22 a, 22 b,and 22 c help to ensure good receipt of the mortar by the masonry unitand increases the length of the interface between the mortar and themasonry unit.

In addition to the preferred dimensions and features described above, amasonry unit according to the present invention may have variousheights. For example, the masonry units shown in FIGS. 1-4 areapproximately half the height of traditional masonry units. In someembodiments, such as the embodiment shown in FIG. 5, the masonry unit310 may have generally the same height as traditional masonry units.Alternatively, masonry units according to the present invention may haveany other appropriate height and various overall length and widthdimensions.

Turning to FIGS. 6-9, the construction of two layers of a wall 25 usingmultiple masonry units 410 according to the present invention will nowbe described. First, as shown in FIG. 6, several masonry units 410 arepositioned in a side-by-side manner (i.e., the horizontally-facing ends16 of the masonry units 410 are disposed proximate one another) suchthat a lower row 30 of a wall 25 is formed (shown with nocross-hatching). Mortar is then placed between the masonry units 410(e.g., within the notches 22 and between the horizontally-facing ends16) and, in some cases, mortar is placed on the upper surfaces of themasonry units 410.

Next, and as depicted in FIGS. 7-9, an upper row 32 of masonry units 410is moved into position on top of the lower row 30. However, the masonryunits 410 in the upper row 32 are vertically inverted relative to thosein the lower row 30 (i.e., the masonry units 410 in the upper row 32each appear similar to the letter S whereas those in the lower row 30each appear similar to a backwards letter S). In addition, the masonryunits 410 in the upper row 32 are horizontally offset relative to thosein the lower row 30 by approximately one half of the overall length ofthe masonry units 410. Again, this is approximate because of theinclusion of mortar between the masonry units 410 makes the distancebetween the repeating pattern established by the masonry units 410slightly greater than the true length of the masonry units 410.

Positioning the masonry units 410 in the lower and upper rows 30 and 32in the above manner provides several advantages. For example, the webs14 of the upper row 32 are stacked vertically upon one of the webs 14 ofthe lower row 32. As such, the webs 14 define a plurality of separatedcontinuous vertical cavities 36 (FIG. 8) that extend through both thelower and upper rows 30 and 32. Referring forward to FIG. 21, a wall 625is shown in which a volume 60 is illustrated that defines one of thecontinuous vertical cavities. Notably, the cross section of the volume60 is generally consistent over the height of the wall 625 and, iffurther rows of masonry units were laid, these rows would furthercontinue to define this column and would not significantly interruptthis volume 60.

As used herein, the term “continuous” and variations thereof, when usedto describe the vertical cavities 36, mean that the shape of thecavities 36 is generally constant as viewed from above as the webs 14align with one another. It will be appreciated that some limited amountof discontinuity may occur at the interfaces between the masonry units410 or where other features have been intentionally introduced (e.g., asdescribed below, the vertically facing open-ended slots 42 configured toreceive horizontal reinforcement rods 44 which may interrupt thecontinuity of the wall of the cavity).

Because of the separation of the cavities 36, grout and/or insulation,etc. is prevented from leaking horizontally into other cavities where itis not desired. Similarly, the separation facilitates vertical drainageof intrusive moisture because it has a clear, uninterrupted pathdownward. There are no webs obstructing the flow as is found withconventional masonry units.

The separated continuous vertical cavities 36 may provide verticalcompartmentalization that inhibits horizontal air movement within thewall 25 (i.e., air movement between different cavities 36). Whencombined with well-known ventilation components (not shown) at the topand bottom of the wall 25, the vertical cavities 36 also facilitatenatural convective airflow that may effectively act as a rain screenwall. Additionally, any moisture that passes through the outermostpartition 12 c of the masonry unit 410 or through voids in the mortarjoints drains down the interior of the vertical cavities 36 and outthrough weep holes (not shown) at the bottom of the wall 25. In thisway, wind-driven moisture is controlled and channeled out of the wall 25to reduce the potential for moisture-induced problems.

In addition, the serpentine transmission paths through the wall 25defined by the horizontally offset webs 14 provide thermal and acousticadvantages. In particular, the serpentine paths define relatively longthermal and acoustic paths connecting the interior and exterior of thewall 25 compared to walls constructed using traditional masonry unitswith single webs that directly connect the front and back walls of themasonry unit. Assuming the material of the masonry unit to be the pathof least resistance for sound or heat, the distance through the wall isa length approximately equal to the thickness of the wall plus thelengthwise distance between the webs 14. Such a long thermal pathsignificantly reduces the rate at which heat may be conducted throughthe wall 25 and, similarly, the long acoustic path significantly reducessound transmission through the wall 25.

Additionally, the wall 25 advantageously provides additional thermalmass to the temperature stability of a building interior. Thermal masscan also reduce the need for supplemental heat in cold environments whenincluded as part of an overall passive solar heating design.

Moreover, as best seen in FIG. 9, the resultant wall has an aestheticconsistent with conventional masonry design. Accordingly, it is possibleif desired to use conventional corners, closed end units, etc. with theimproved masonry unit.

Referring now to FIGS. 10-20, walls formed by masonry units according tothe present invention may include various additional components andmaterials to enhance their characteristics. For example and referring toFIG. 10, one or more of the separated continuous vertical cavities 36 ofa wall 125 may house one or more vertical reinforcement rods 38 (e.g.,steel rods). As described briefly above, when constructing a wall, themasonry units may simply be moved horizontally relative to thereinforcement rods 38 to receive the rods. As such and unliketraditional masonry units, the masonry units according to the presentinvention do not need to be lifted above and subsequently lowered overthe reinforcement rods 38. This provides three distinct advantages overwalls constructed using traditional masonry units. First, labor costsare reduced because constructing the wall requires less time. Second,the potential for shoulder and back strains are reduced due to thereduced amount of masonry unit lifting. Third, the total length ofreinforcement material is reduced because longer lengths of verticalsrods can be used. This minimizes the number of rod overlaps, ties,and/or couplers.

As another example and referring to FIG. 11, one or more of theseparated continuous vertical cavities 36, such as the cavities 36proximate the outermost partition 12 c, may receive insulation 40. Othertypes of insulation may alternatively be used. Depending on the typethat is used, the insulation 40 can be pre-installed into the masonryunit or added after the wall 225 is constructed. The insulation 40 mayalso be shaped to receive one of the vertically-extending supports 21 ofthe masonry units. Regardless of the type and specific shape that isused, the insulation further reduces the thermal conductivity throughthe wall and provides further moisture control.

As yet another example and referring now to FIGS. 12 and 13, in someembodiments, masonry units 510 according to the present invention mayfurther include features to receive horizontally-extending supports. Inparticular, the webs 14 of the masonry units 510 include verticallyfacing open-ended slots 42 configured to receive horizontalreinforcement rods 44. The masonry units 510 and horizontalreinforcement rods 44 may be used to construct one or more rows of thewall 325.

A wall formed by masonry units according to the present invention mayalternatively have other types of horizontal reinforcements. For exampleand referring to FIG. 14, the wall 425 may include one or morehorizontal “ladder” reinforcement structures 46 between rows of masonryunits 410. As another example and referring to FIG. 15, the wall 525 mayinclude one or more horizontal “truss” reinforcement structures 48.

Walls formed by masonry units according to the present invention mayinclude combinations of the above components and materials. For exampleand referring to FIG. 16, the masonry units 110 may house both thevertical reinforcement rods 38 and the insulation 40. As another exampleand referring to FIG. 17, the masonry units 410 may support a horizontal“truss” reinforcement structure 48 and house insulation 40 within mostof the separated continuous vertical cavities 36. Some of the separatedcontinuous vertical cavities 36 proximate the innermost partitions 12 aalso house vertical reinforcement rods 38 and reinforcement grout 50.Referring to FIG. 18, the masonry units 410 may support a horizontal“truss” reinforcement structure 48 and house insulation 40 within mostof the separated continuous vertical cavities 36. Some of the separatedcontinuous vertical cavities 36 proximate the innermost partitions 12 aand proximate the outermost partitions 12 c also house verticalreinforcement rods 38 and reinforcement grout 50.

Referring to FIG. 19, the masonry units 410 may support a horizontal“truss” reinforcement structure 48 and house insulation 40 within mostof the separated continuous vertical cavities 36. The insulation 40proximate the outermost partitions 12 c includes protrusions 52 thatspace the insulation 40 apart from the outermost partitions 12 c anddefine air gaps 54 within the separated continuous vertical cavities 36which provide channels for ventilation. In addition, some of theseparated continuous vertical cavities 36 proximate the innermostpartitions 12 a also house vertical reinforcement rods 38 andreinforcement grout 50. Referring to FIG. 20, the masonry units 410 maysupport a horizontal “truss” reinforcement structure 48 and houseinsulation 40 within most of the separated continuous vertical cavities36. The insulation 40 proximate the outermost partitions 12 c includesprotrusions 52 that space the insulation 40 apart from the outermostpartitions 12 c and define air gaps 54 within the separated continuousvertical cavities 36. In addition, some of the separated continuousvertical cavities 36 proximate the innermost partition 12 a andproximate the outermost partition 12 c also house vertical reinforcementrods 38 and reinforcement grout 50.

Masonry units and walls constructed therefrom according to the presentinvention may further vary from those described above. For example,conventional masonry fittings can be used in conjunction with themasonry units. In particular, corner units, closed end units, bondbeams, and the like can be utilized with the masonry units in a wallstructure. As another example, the separated continuous verticalcavities 36 may additionally or alternatively house components such asplumbing lines, electrical wiring, and data/communication cables.

Materials used to manufacture the invention are typically sand, stone,Portland cement, and water. Cementitious substitutes such as flyash,ground granulated blast furnace slag, cement kiln dust, silica flour andsilica fume may alternatively be used. Iron oxides may be used toprovide color, and admixtures may be used to aid in manufacturing orprovide or enhance certain properties of the masonry units.

Masonry units according to the present invention may be manufacturedusing a concrete block machine such those manufactured by Besser Co.,Columbia Machine, Tiger, or the like, using a concrete paver machinesuch those manufactured by Columbia Machine, Tiger, Masa, Hess, or thelike, or using other similar machines. The masonry units may also bemanufactured using a wetcast process in which concrete with a measurableslump is placed into a mold and consolidated prior to curing. Asdescribed briefly above, the vertically upright supports 21 a and 21 bconnected to the partitions 12 a and 12 c, respectively, provide supportfor the partitions 12 a and 12 c during fabrication and subsequenttransport of the masonry unit.

When the masonry units are manufactured using a block or paver machine,the forming mold can be fabricated in various manners. The complete moldconsists of two main assemblies: the mold and the head.

One mold design is consistent with traditional block molds. This designutilizes metal wear partitions of various shapes and dimensions, made ofhardened material, that are bolted into position in a rigid metal frameto create the mold.

Another mold design is consistent with traditional paver molds. Thisdesign utilizes a one-piece hardened-metal insert that is bolted intothe mold. The insert is typically formed from a piece of steel or otherwear-resistant material from which material is removed to form cavitiesof various shapes. These cavities define the shape of the mold. The headassembly consists of a top partition, plungers, and shoes. The variousparts can be welded or bolted together.

It should be appreciated that while masonry units have been shown withthree parallel partitions and two webs that can be used to form a wallhaving two rows of separated continuous vertical cavities therein, thatmasonry units having more than two rows of separated continuous verticalcavities can be made by adding additional partitions and webs. Forexample, three rows of separated continuous vertical cavities might beformed using a masonry unit having four partitions with three webs. Inthis instance, the two outermost webs may be co-planar with one anothersuch that the first and third rows have aligned vertical cavities.

From the above description, it should be apparent that the masonry unitsand walls constructed therefrom according to the present inventionprovide various advantages over traditional masonry units and walls. Inparticular, the masonry units facilitate faster and easier constructionof masonry walls with vertical reinforcement versus traditional masonrywalls with vertical reinforcement. The labor associated withconstruction of a wall using masonry units according to the presentinvention is estimated to be less than half of that required fortraditional multi-wythe walls. As such, the masonry units provideconstruction cost advantages through material, time, and labor savings.

Similarly, the masonry units and walls constructed therefrom alsoperform the functions of traditional multi-wythe walls. In particular,the masonry units provide multiple columns of separated continuousvertical cavities that can be utilized for placement of reinforcingmaterials, insulation, moisture control mechanisms, plumbing, electricalwiring, ventilation, data/communication cables, and the like.

Preferred embodiments of the invention have been described inconsiderable detail. Many modifications and variations to the preferredembodiments will be apparent to a person of ordinary skill in the art.Therefore, the invention should not be limited to the embodimentsdescribed, but should be defined by the claims that follow.

1. A masonry unit for constructing a wall, the masonry unit comprising:at least three substantially vertical parallel partitions extendingalong a lengthwise direction, each of the partitions being connected toan adjacent partition by a web extending in a widthwise direction,thereby defining a pair of oppositely-facing open-ended recesses oneither side of the web, each of the webs connecting the partitions beingoffset in the lengthwise direction from any adjacent web in the masonryunit; wherein, when the wall is formed from a plurality of the masonryunits by positioning multiple rows of stacked masonry units on top ofeach other in a horizontally offset and vertically inverted manner, aplurality of separated continuous vertical cavities extending throughthe multiple rows are formed within the wall.
 2. The masonry unit ofclaim 1, further comprising a vertically-extending support formed alongone at least one of the partitions to provide support for the partitionduring fabrication of the masonry unit.
 3. The masonry unit of claim 2,wherein the vertically-extending support is aligned with one of the websin the lengthwise direction.
 4. The masonry unit of claim 1, wherein themasonry units are configured such that, if a second row of masonry unitsis stacked on top of a first row of masonry units in a verticallyinverted manner and are horizontally offset approximately one-half anoverall length of the masonry unit from the first row, then the webs ofthe masonry units in the first row and the second row are verticallyaligned with one another.
 5. The masonry unit of claim 4, wherein eachof the webs is offset from any adjacent webs in the lengthwise directionof the masonry unit by substantially one half of the overall length ofthe masonry unit.
 6. The masonry unit of claim 4, wherein each of thewebs is offset from ends of the partitions in the lengthwise directionof the masonry unit by substantially one quarter of the overall lengthof the masonry unit.
 7. The masonry unit of claim 1, wherein at leastone web includes a vertically facing open-ended slot configured toreceive a horizontal reinforcement rod.
 8. The masonry unit of claim 1,wherein the partitions and the webs comprise cement.
 9. The masonry unitof claim 1, wherein each of the partitions integrally connects to theadjacent partitions by the webs.
 10. The masonry unit of claim 1,wherein the masonry unit is generally rectangular shaped.
 11. A masonryunit for constructing a wall, the masonry unit comprising: a firstvertical partition; a second vertical partition substantially parallelto the first vertical partition and offset from the first verticalpartition in a first horizontal direction; a third vertical partitionsubstantially parallel to the first vertical partition and the secondvertical partition and offset from the second vertical partition in thefirst horizontal direction; a first web connecting the first verticalpartition and the second vertical partition and thereby definingopen-ended recesses on both sides of the first web facing away from eachother along a second horizontal direction substantially perpendicular tothe first horizontal direction; a second web connecting the secondvertical partition and the third vertical partition and thereby definingopen-ended recesses on both sides of the second web facing away fromeach other along the second horizontal direction; and wherein themasonry unit has an overall length in the second horizontal direction,the first web is offset from the second web in the second horizontaldirection by a web offset distance, and the web offset distance issubstantially one half of the overall length such that, when the wall isformed using the masonry units by positioning multiple layers of stackedmasonry units together in a horizontally offset and inverted manner, aplurality of separated continuous vertical cavities extending throughthe multiple layers are formed within the wall.
 12. The masonry unit ofclaim 11, wherein the first vertical partition includes avertically-extending support disposed in one of the open-ended recessesdefined by the first web to provide support for the first verticalpartition during fabrication of the masonry unit.
 13. The masonry unitof claim 12, wherein the vertically-extending support is aligned withthe second web in the second horizontal direction.
 14. The masonry unitof claim 11, wherein horizontally-facing ends of the first verticalpartition include open-ended notches facing away from each other alongthe second horizontal direction and being configured to receive mortarto connect the masonry units in the wall.
 15. The masonry unit of claim11, wherein the first web includes a vertically facing open-ended slotconfigured to receive a horizontal reinforcement rod.
 16. The masonryunit of claim 11, wherein the first web is offset from an end of thefirst vertical partition facing in the second horizontal direction by ahorizontal offset distance, the second web is offset from an end of thethird vertical partition facing in the second horizontal direction bythe horizontal offset distance, and the horizontal offset distance issubstantially one quarter of the overall length.
 17. A masonry unit forconstructing a wall, the masonry unit comprising: a first verticalpartition; a second vertical partition substantially parallel to thefirst vertical partition and offset from the first vertical partition ina first horizontal direction; a third vertical partition substantiallyparallel to the first vertical partition and the second verticalpartition and offset from the second vertical partition in the firsthorizontal direction; a first web connecting the first verticalpartition and the second vertical partition and thereby definingopen-ended recesses on both sides of the first web facing away from eachother along a second horizontal direction substantially perpendicular tothe first horizontal direction; a second web connecting the secondvertical partition and the third vertical partition and thereby definingopen-ended recesses on both sides of the second web facing away fromeach other along the second horizontal direction; and wherein themasonry unit has an overall length in the second horizontal direction,the first web is offset from an end of the first vertical partitionfacing in the second horizontal direction by a horizontal offsetdistance, the second web is offset from an end of the third verticalpartition facing in the second horizontal direction by the horizontaloffset distance, and the horizontal offset distance is substantially onequarter of the overall length such that when wall is formed using themasonry units by positioning multiple layers of stacked masonry unitstogether in a horizontally offset and inverted manner, a plurality ofseparated continuous vertical cavities extending through the multiplelayers are formed within the wall.
 18. The masonry unit of claim 17,wherein the first vertical partition includes a vertically-extendingsupport disposed in one of the open-ended recesses defined by the firstweb to provide support for the first vertical partition duringfabrication of the masonry unit.
 19. The masonry unit of claim 18,wherein the vertically-extending support is aligned with the second webin the second horizontal direction.